Hard turning machines for industrial production
How a hard turning machine works
The hard turning machine is a high-precision machine tool that is specially designed for machining hardened steels with a hardness of over 45 HRC. It is an economical alternative to grinding, as it enables shorter machining times and lower set-up costs with comparable surface quality. It is primarily used for finishing hardened workpieces in a single machining step - i.e. without downstream processes such as grinding.
Structure of a hard turning machine
A hard turning machine consists of particularly stable and precisely manufactured components. The machine bed provides the necessary rigidity and damping. The headstock with high-precision spindle enables the rotating clamping of the workpiece. The tool turret or a tool carrier holds specially hardened cutting tools. Linear guides and ball screw spindles guarantee precise movements of the axes. Controls with high-resolution measuring systems regulate the process in real time. The equipment also includes cooling lubricant systems and, in many cases, automation solutions such as workpiece changers.
Production with the hard turning machine
The machining process on a hard turning machine is usually carried out using high-strength cutting materials such as CBN (cubic boron nitride) or ceramic cutting materials. These are able to penetrate the high hardness of the workpiece material and at the same time ensure very high dimensional and shape accuracy. Typically, extremely rigid machine components and low-vibration designs are used to ensure the necessary process stability. The machines are usually equipped with modern control systems that enable high-precision axis movements and automatic adjustment of the machining parameters.
During hard turning, the workpiece rotates at high speed while the tool is guided along defined paths. This creates the chip through which the material is removed to shape it. Despite the high material hardness, chip removal and feed are much more efficient with hard turning than with grinding. Even complex geometries can be realised in a single clamping operation. The trend is towards complete machining on a single machine, which not only saves costs, but also space and energy.
Hard turning machines are an indispensable part of modern production lines in the automotive, roller bearing and hydraulics industries when it comes to the precise finishing of hardened components.
The following search terms are frequently used on this topic: Machine hard turning, hard turning machines, turning machine for hard turning, CNC hard turning.
Hard turning
Advantages of hard turning
Hard turning often replaces grinding and enables economical complete machining in a single clamping operation. Machining times are shorter and tool and set-up costs are lower. Complex geometries can also be machined flexibly. Other advantages include dry machining and a lower environmental impact.
Disadvantages of hard turning
Disadvantages include the high demands on machine rigidity and tool quality as well as limited options for extremely small tolerances or mirror-smooth surfaces. Tool wear is also high if the wrong parameters are selected. Expertise in process design is essential for optimum results.
Accuracy and surface quality
Surface finishes of up to Ra 0.2 µm can be achieved with a hard turning machine, which corresponds to the quality of ground surfaces. With optimised machining parameters, high-quality CBN tools and a low-vibration machine design, even Rz values of less than 1 µm are possible. Cutting speed, feed rate, infeed and tool geometry are decisive for the quality achieved. Through targeted process control, not only high dimensional accuracy can be achieved, but also a fine, uniform surface that is often directly functional without additional post-processing. This is particularly advantageous when finishing hardened bearing and sealing surfaces.
Application in industrial metalworking
Hard turning machines are mainly used where hardened components need to be precisely machined. Typical sectors include the automotive industry, mechanical engineering, aerospace technology and the bearing and hydraulics industry. Hard turning is also used in medical technology and in the manufacturer of tool moulds.
Typical workpieces that are manufactured or finished on a hard turning machine are
- Gear shafts
- gear wheels
- Rolling bearing rings
- valve parts
- Spindle housings
- injection components
- brake discs
- bushes
- Piston rods
- Chuck components
Thanks to the high precision of hard turning, tight tolerances and fine surface qualities can be realised.
Tools for a hard turning machine
High-strength, wear-resistant tools are required for hard turning. Indexable inserts made of CBN (cubic boron nitride) are used most frequently. Other typical tools are
- Ceramic indexable inserts
- Carbide tools with a special coating
- Multicut tools
- Internal machining tools
- Grooving tools
- Mould turning tools
- Quick-change holders
- Tool holders with coolant supply
- Fine machining tools
- Combination tools for external and internal machining
These tools enable a long tool life and the achievement of fine surfaces.
The following terms are often used when searching for tools: Hard turning tools, hard turning indexable inserts, indexable inserts hard turning, hard turning with CBN, CBN hard turning, DTS hard turning, Horn hard turning, Mitsubishi hard turning, hard turning Sandvik, Sandvik hard turning, Sumitomo hard turning, Tungaloy hard turning
Accessories and operating materials for a hard turning machine
A number of accessories are required to operate a hard turning machine. These include clamping devices such as precision chucks, tool holders and changing systems. A powerful cooling lubricant system is necessary to efficiently remove heat and chips. Equally important are measuring systems for process control and possibly automatic loading units for series production. High-quality lubricants, hydraulic oil and coolants that are especially suitable for high-precision machines are required as operating fluids.
Leading manufacturers of hard turning machines
In our manufacturers directory you will find companies that manufacture hard turning machines for metalworking.
The following terms are frequently searched for: Benzinger hard turning, DANOBAT-OVERBECK hard turning machine, DMG MORI hard turning, DVS Technology hard turning machine, Erwin Junker Maschinenfabrik hard turning machine, hard turning Hardinge, Hardinge hard turning, Hembrug hard turning, J.G. WEISSER SÖHNE hard turning machine, MAG IAS hard turning machine, Monforts WZM hard turning machine, Monnier + Zahner hard turning machine, PECO Werkzeugmaschinen hard turning machine, Precitrame Machines hard turning machine, Soraluce Spain hard turning machine, Spinner Werkzeugmaschinenfabrik hard turning machine, Studer hard turning machine
Choosing the right hard turning machine
If you want to buy a hard turning machine, there are several important features and specifications to consider.
- Firstly, pay attention to the maximum workpiece size as well as the axis configuration and guide type - linear guides, for example, offer greater dynamics.
- The spindle power and Speed are decisive for material removal.
- Machine rigidity is also important in order to avoid vibrations and ensure consistent surface quality.
- Controls with high-resolution path measuring systems ensure reproducible precision.
- The machine should have an efficient cooling lubrication system and suitable interfaces for automation and measurement technology.
- Integrated measuring systems or sanding units for combined machining are useful options.
- The availability of service and spare parts also plays a major role in the investment decision.
Find the hard turning machine that suits your production requirements now at maschinenauswahl.de.
You can find other types of turning machines in our "Turning" section.
Note
This page answers the following questions, among others:
- What is hard turning?
- What is the definition of hard turning?
- For what purpose is hard turning used?
- What accuracy can I achieve with hard turning?
- What surface quality can I achieve with hard turning?
- What are the disadvantages of hard turning?
- Who are the manufacturers of hard turning machines?
- What types of turning machines are there?
- What is hard turning called in English?